242-3567 Variable Crimp Die Bowl{0684} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

Do not weld

No smoking

Hazard Avoidance

Crushing hazard

Crushing hazard (foot)

Crushing hazard (hand)

Fire hazard

Pinch point

Pressurized air

Safety alert symbol

Slipping hazard

Tripping hazard

Safety Warnings

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills.

General Information Section

Introduction

The 242-3567 Bowl provides infinite crimp diameter adjustment when making hose assemblies. Using this die bowl eliminates the need for spacer rings. The variable crimp die bowl uses an internal thread to raise and lower the height or thickness of the die bowl. Micrometer-like markings on the bowl halves allow the user to quickly and accurately adjust the thickness of the bowl. The variable crimp die bowl is used with Caterpillar-style dies on all coupling types except 1543 Air Conditioning Hose Couplings.

References

Wall Chart, NEEG3000, "Variable Die Bowl Crimp Diameter Chart"Tool Operating Manual, NEHS0643, "Using the 233-7191, 233-7192, and 233-7193 Hose Cleaner Groups"Tool Operating Manual, NEHS0686, "Setup and Operation of the 139-5439 Combination Hose Machine"Tool Operating Manual, NEHS0745, "Assembling Reusable Couplings in the 4C-9900, 150-2568, and 173-9805 Hydraulic Hose Machines"Tool Operating Manual, NEHS0746, "Assembling Reusable Couplings in the 139-5439, 145-3381, and 152-3910 Combination Hose Machines"Tool Operating Manual, NEHS0768, "General Information for Hose Assembly"Tool Operating Manual, NEHS0902, "243-0765 Bench Model Hose Machine for Use With 242-3567 Variable Crimp Die Bowl"Wall Chart, NEEG2955, "Hose Cleaner Projectile Sizing Chart for Hose and Hose Assemblies"Wall Chart, NEEG2956, "Skive Length Chart", PECP5030, "CAT Hose and Couplings Reference Guide"

Note: The list of references above may change, always locate, and refer to the appropriate manual for required service information.

Additional Contact Information

For additional product support questions concerning this tool, contact the Cat Dealer Service Tools Hotline at:

U.S.A.: 1-800-542-8665Illinois: 1-800-541-8665Canada: 1-800-523-8665World: 1-309-675-6277Fax: 1-309-494-1355

dealerservicetool_hotline@cat.com

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

Specifications

Table 1

Hose Machine Capabilities Chart (Maximum Hose Size)
Hose Type	243-0765 Hose Machine Gp	209-3153 Hose Machine Gp	150-2568 Hose Machine Gp	139-5439 Hose Machine Gp
294	-20	-20	-20	-20
716	-20	-20	-20	-20
844	-20	-20	-20	-20
1956	-20	-16	-16	-20
XT-3 ES	-20	-16	-16	-20
XT-5	-16	-12	-12	-16
XT-6	-12	-8	-12	-12
XT-6 ES	-16	-8	-12	-16
1543	-14	-14	-14	-14
1028	-12	-12	-12	-12
2760	-8	-8	-8	-8

Setup

Die Bowl Assembly

The 242-3567 Bowl must be assembled from the parts listed in the 2below.

Note: The 242-3567 Bowl is a two-piece, matched set. These two parts are not serviced separately.

Illustration 3	g02175767

Table 2

Required Parts
Item	Part No.
(1)	242-3567 Bowl
2	133-7362 Seat (DIE)
(3)	4C-4376 Retaining Ring
(4)	4C-4375 Spring
(5)	140-9360 Spacer Ring
(6)	135-4561 Separator

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Illustration 4	g02175783

1. Place 135-4561 Separator (6) into the bottom side of 242-3567 Bowl (1). The notches on the die separator should be pointing down toward the work surface of the table.

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Illustration 5	g02175809

2. Place 140-9360 Spacer Ring (5) into the bottom side of die bowl.

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Illustration 6	g02175816

3. Place 4C-4375 Spring (4) into the bottom side of die bowl (tapered end down).

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Illustration 7	g02175817

4. Compress the spring and insert 4C-4376 Retaining Ring (3) into the snap ring groove of the variable die bowl.

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Illustration 8	g02176159

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Illustration 9	g02176158

5. Turn the die bowl over and place 133-7362 Seat (DIE) (2) into die separator (6) from the top side of die bowl.

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Illustration 10	g02176160

6. The variable crimp die bowl is now fully assembled and ready to use with Caterpillar dies. Refer to the Tooling Parts List section for a list of the die part numbers used with the variable crimp die bowl.

Variable Crimp Die Bowl

Using the Adjustment Scale

Illustration 11	g02176555

The variable crimp die bowl uses two scales to determine the height or thickness of the bowl. The die bowl works exactly like a machinist micrometer. The increment setting marks (vertical) around the top of the bowl (7) range from 0 to 0.95 mm. One full revolution of the top bowl is equal to 1.0 mm of crimp diameter adjustment. The horizontal marks on the bottom of the bowl (8) range from 0 to 3.0 mm. The long marks are full millimeters, while the short marks represent one-half of a millimeter.

Note: Do not forcefully screw the two halves of the die bowl together to a setting of zero (0). The closely machined surfaces of the die bowl can lock together, making the die bowl difficult to separate.

Setting the Variable Die Bowl

1. Adjust the die bowl to zero.

2. Determine the hose type being assembled.

3. Refer to Wall Chart, NEEG3000, "Crimp Diameter Chart" and locate the crimp specifications for the selected hose type.

4. Set the bowl, using the calibration marks Wall Chart, NEEG3000, "Crimp Diameter Chart" ""Calculating the Bowl Setting Number" "to determine the bowl setting.

To set the die bowl for a 1.75 mm "Bowl Setting", first adjust the bowl to zero (0). Now rotate the top half of the bowl one complete revolution counterclockwise and set the bowl at 1.0 mm. Again, turn the bowl counterclockwise until the 0.75 mark aligns with the zero mark. The variable crimp die bowl is now set to 1.75 mm.

Calculating the Bowl Setting Number

If the Wall Chart, NEEG3000, "Crimp Diameter Chart" chart is not available, a simple formula can be used to determine the die bowl setting. Bowl Setting = Crimp Diameter - Die Pin Bore Diameter Refer to 3 pin bore size of dies used in the variable crimp die bowl.

Table 3

Part No.	Pin-Bore	Part No.	Pin-Bore
241-9133	12 mm	241-9141	28 mm
241-9134	14 mm	241-9142	30 mm
241-9135	16mm	241-9143	33mm
241-9136	18mm	241-9144	37mm
241-9137	20mm	241-9145	40mm
241-9138	22mm	241-9146	43mm
241-9139	24mm	220-8686	48mm
241-9140	26mm	241-9147	50mm

1. Example for 1028-3 hose.

2. Enter specified crimp diameter 12.45.

3. Subtract the 241-9133 Die pin-bore diameter.

4. Bowl setting will be the difference 0.45.

Modifying the 136-3642 Crimp Tool

Illustration 12	g02176737

The 136-3642 Crimp Tool is made up of three parts, upper pusher plate (9), lower pusher plate (10), and sleeve (11). Before using the 136-3642 Crimp Tool on the XT-Style Hose Machines or the Combination-Style Hose Machines, the sleeve must be modified or replaced with a new 243-0579 Sleeve . To modify an existing sleeve, simply machine the top surface of the sleeve to obtain a total thickness of 39.3 ± 1.5 mm (1.54724 ± 0.05906 inch) 39.3 mm as shown in the illustration.

Illustration 13	g02176742

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NOTICE
Once the sleeve has been modified, the sleeve cannot be reused in the crimp tool group with other die groups.

Operation

General Hose Assembly Guidelines

Producing high-quality hose assemblies requires observing the following general guidelines.

1. Cut the ends of the hose as square as possible.

2. Clean the inside of the hose of all dirt and debris. One of the 233-7191 Hose Cleaner Gp 233-7193 Hose Cleaner Gp 233-7192 Hose Cleaner Gp is recommended for cleaning the hose. Refer to Tool Operating Manual, NEHS0643, "Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups" for more detailed instructions on cleaning hoses.

3. Insert the hose in the new coupling until the hose is aligned with the coupling insertion mark. Refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly" for additional information. Do not allow oil or grease on the hose or couplings. Only water is permitted as a lubricant when placing couplings onto hoses.

   Note: When crimping 1543 Air Conditioning Hose Couplings, carefully seat the coupling against the locating tab in the die group before crimping.

4. Sharp edges and burrs on crimped couplings can be removed with 80 grit emery paper or other suitable mean

5. To maintain the quality of each hose assembly, measure the finished crimp diameter to make sure that the crimp meets the correct assembly specifications. Crimp diameters can be measured using a micrometer, calipers, or caliper measurement system.

   Note: Use Wall Chart, NEEG3000, "Crimp Diameters Chart ", for crimp diameter specifications. Refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly" for additional information on measuring hose coupling crimp diameters.

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   Table 4

   Crimp Measurement Tooling
   136-0536	Caliper
   136-0538	Cable
   136-0539	Foot Switch
   136-0544	Mini Processor
   136-4219	AC Adapter
   9U-6690	Replacement Ribbon
   136-0543	Paper Rolls

6. Clean each hose after assembly.

   1. Tap both ends of the hose to remove any large particles.

   2. Use one of the 233-7193 Hose Cleaner Gp 233-7191 Hose Cleaner Gp 233-7192 Hose Cleaner Gp to clean the inside diameter of the hose assembly. A cleaning projectile should be sent through each end of the hydraulic hose. Refer to Tool Operating Manual, NEHS0643, "Using the 233-7191 233-7192 233-7193 Hose Cleaner Group "

Hose Machine Operation

243-0765 Hydraulic Hose Machine Gp and 209-3153 Hydraulic Hose Machine Gp

Illustration 14	g02176647
The 243-0765 Hydraulic Hose Machine Gp (9) and 209-3153 Hydraulic Hose Machine Gp (10)

1. Select the appropriate die from Wall Chart, NEEG3000, "Crimp Diameter Chart" or refer to table 6 of this manual.

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Illustration 15	g02176661

2. Set the variable die bowl to the correct bowl setting reference number found in the Wall Chart, NEEG3000, "Crimp Diameter Chart".

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Illustration 16	g02176668

3. Find the crimp length on Wall Chart, NEEG3000, "Crimp Diameter Chart" and mark that length on the hose coupling.

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Illustration 17	g02177476

4. Insert the variable crimp die bowl and the proper die into the hose machine.

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Illustration 18	g02176677

5. Align the crimp length mark on the coupling with the top of the die.

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Illustration 19	g02176678

6. Install the front pusher plate.

7. Lower the pusher plate until the plate touches the top of the variable crimp die bowl.

8. Raise the pusher plate, remove the hose assembly, and check the crimp diameter. Refer to Wall Chart, NEEG3000, "Crimp Diameter Chart" for crimp diameter specifications.

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Illustration 20	g02176686

9. Measure the crimp diameter refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly"

10. If necessary, adjust the variable crimp die bowl to make the crimp diameter of the next hose assembly as close as possible to the specified crimp diameter. Write this new bowl setting number in the "Actual Setting" column of Wall Chart, NEEG3000, "Crimp Diameter Chart". Using this new number should provide a more accurate crimp diameter the next time the die is used to crimp a hose coupling.

4C-9900 Hydraulic Hose Press Gp 6V-4880 Hydraulic Hose Press Gp 1U-9160 Hydraulic Hose Press Gp 150-2568 Hydraulic Hose Machine Gp 173-9805 Hydraulic Hose Machine Gp XT-Style Hose Machines

Illustration 21	g02176749

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Illustration 22	g02176661

1. Select the appropriate die from Wall Chart, NEEG3000, "Crimp Diameter Chart" or refer to table 6 of this manual.

2. Set the variable die bowl to the correct "Bowl Setting"reference number found in Wall chart, NEEG3000, "Crimp Diameter Chart".

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Illustration 23	g02176668

3. Find the crimp length on Wall Chart, NEEG3000, "Crimp Diameter Chart" and mark that length on the hose coupling.

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Illustration 24	g02177485

4. Insert the modified 136-3642 Crimp Tool Group into the hose machine. See ""Modifying the 136-3642 Crimp Tool Group " "for specific rework instructions.

   Note: The XT hose machines must be placed in the vertical position before crimping a hose assembly with this tooling.

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Illustration 25	g02176760

5. Insert the variable die bowl into the hose machine.

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Illustration 26	g02176762

6. Align the crimp length mark on the coupling with the top of the die.

7. Lower the pusher plate until the plate touches the top of the variable crimp die bowl.

8. Raise the pusher plate, remove the hose assembly, and check the crimp diameter. Refer to Wall Chart, NEEG3000, "Crimp Diameter Chart" for crimp diameter specifications.

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Illustration 27	g02176686

9. Measure the crimp diameter refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly".

10. If necessary, adjust the variable crimp die bowl to make the crimp diameter of the next hose assembly as close as possible to the specified crimp diameter. Write this new bowl setting number in the "Actual Setting" column of Wall Chart, NEEG3000, "Crimp Diameter Chart". Using this new number should provide a more accurate crimp diameter the next time the die is used to crimp a hose coupling.

139-5439 Hydraulic Hose Machine Gp 145-3381 Hydraulic Hose Machine Gp 152-3910 Hydraulic Hose Machine Gp Combination Style Hose Machines

Illustration 28	g02176784

1. Select the appropriate die from Wall Chart, NEEG3000, "Crimp Diameter Chart" or refer to table 6 of this manual.

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Illustration 29	g02176661

2. Set the variable die bowl to the correct "Bowl Setting"reference number found in Wall chart, NEEG3000, "Crimp Diameter Chart".

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Illustration 30	g02176668

3. Find the crimp length on Wall Chart, NEEG3000, "Crimp Diameter Chart" and mark that length on the hose coupling.

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Illustration 31	g02177691

4. Insert the modified 136-3642 Crimp Tool into the hose machine. See ""Modifying the 136-3642 Crimp Tool " "for specific rework instructions.

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Illustration 32	g02177692

5. Lower the two lock bars into place, but do not tighten the holding screws. Insert the variable die bowl into the crimp tool group.

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Illustration 33	g02177696

6. Align the crimp length mark on the coupling with the top of the die.

7. Make sure the upper and lower pusher plates are pushed completely into the hose machine. Lower the pusher plate until the plate touches the top of the variable die bowl.

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Illustration 34	g02176686

8. Raise the pusher plate, remove the hose assembly, and check the crimp diameter. Refer to Wall Chart, NEEG3000, "Crimp Diameter Chart" for crimp diameter specifications.

9. Measure the crimp diameter refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly"

10. If necessary, adjust the variable crimp die bowl to make the crimp diameter of the next hose assembly as close as possible to the specified crimp diameter. Write this new bowl setting number in the "Actual Setting" column of Wall Chart, NEEG3000, "Crimp Diameter Chart". Using this new number should provide a more accurate crimp diameter the next time the die is used to crimp a hose coupling.

Crimping 1543 Air Conditioning Couplings

1E1543 Air Conditioning Couplings can be crimped using the variable crimp die bowl by removing the 133-7362 Seat (DIE) and using the appropriate die. Refer to Wall Chart, NEEG3000, "Crimp Diameter Chart" for the bowl setting and die group part number for the coupling being assembled. For additional information refer to Tool Operating Manual, NEHS0749, "Crimping 1E1543 Air Conditioning Hose and 1E1028 Thermoplastic Hose".

Illustration 35	g02176941

Illustration 36	g02176943

Maintenance

1. Clean all dirt and debris off the outside diameter. Also clean the inside diameter of the bowl and the tapered surface.

2. Lubricate the bowl with 129-1939 High Temperature Grease or equivalent.

Inspection

Inspect the die bowl parts daily for damage or abnormal wear. Replace all worn or damaged parts immediately.

Tooling Parts List

Table 5

Variable Crimp Die Bowl
Part No.	Description
133-7362	Die Rest
242-3567	Die Bowl
135-4561	Die Separator
140-9360	Separator Ring
4C-4375	Spring
4C-4376	Snap Ring

Table 6

All Die Groups (except 1543
Part No.	Die Inside Diameter
241-9133	12 mm
241-9134	14 mm
241-9135	16 mm
241-9136	18 mm
241-9137	20 mm
241-9138	22 mm
241-9139	24 mm
241-9140	26 mm
241-9141	28 mm
241-9142	30 mm
241-9143	33 mm
241-9144	37 mm
241-9145	40 mm
241-9146	43 mm
220-8686	48 mm
241-9147	50 mm

Table 7

1543 Die Groups
4C-3675	-6
4C-3676	-8
214-5155	-10
4C-3677	-12
189-0990	-14

Table 8

Crimp Measurement Tooling
Part No.	Description
136-0536	Caliper
136-0538	Cable
136-0539	Foot Switch
136-0544	Mini Processor
136-4219	AC Adapter
9U-6690	Replacement Ribbon
136-0543	Paper Rolls

Table 9

Crimp Tool Group
Part No.	Description
136-3642	Crimp Tool Group
243-0579	Sleeve

Note: Sleeve must be modified or replaced with 243-0579 Sleeve .